When an industrial hose fails, the problem is rarely small. It’s not just a case of swapping out one part - the knock-on effects can ripple across an entire operation. A split hose or failed connection can mean unplanned downtime, lost production, safety hazards for staff, and even costly environmental clean-up if fluids or powders spill.
The positive news is that most of these failures are preventable. With regular inspections and a simple maintenance routine, you can extend the life of your hoses, reduce unplanned stoppages, and keep your workforce safe.
Why Regular Hose Checks Matter
Hoses are the unsung heroes of industrial sites. They carry the materials that keep your operation moving - whether that’s water in a washdown, compressed air for tools, or fuels, chemicals, powders and slurries in process systems.
This heavy workload puts hoses under constant stress. Over time, materials naturally degrade. Rubber may harden, reinforcement layers can weaken, and couplings may loosen. Without routine checks, these small issues can go unnoticed until they result in major failures.
Introducing a planned hose inspection schedule offers clear benefits:
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Improved reliability - avoid unplanned downtime and keep processes running smoothly
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Greater safety - spot potential hazards before they put people at risk
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Cost savings - extend hose service life and reduce the need for expensive emergency replacements
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Compliance support - meet industry requirements and avoid regulatory issues
In short, proactive inspection is about more than protecting equipment. It’s about protecting people, productivity and profit.
What to Look for During an Inspection
Not every fault is obvious. While some hoses may clearly split or crack, many issues start small and worsen over time. A good inspection should cover both the hose itself and its fittings.
Here are some of the most common signs to look out for:
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Surface wear - scratches, scuffs or worn outer layers are often caused by abrasion against machinery, floors or other hoses. Left unchecked, this weakens the hose wall.
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Blisters or swelling - these can suggest pressure build-up inside the hose or damage to its internal lining.
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Cracks and splits - especially near bends or ends, where the hose flexes most.
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Stiffness - if a hose loses flexibility, it may have aged or been exposed to heat or chemicals that degrade its structure.
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Corroded fittings - rust, pitting or wear on metal ends or couplings weakens the whole assembly and increases the chance of leaks.
The goal of inspection is not only to identify damage but also to assess whether a hose is still suitable for its current duty. A hose designed for water may not last long if it’s repurposed for fuel or chemicals, for example.
Why Fittings and Connections Matter
Hose failures often start at the ends. The coupling or clamp is where most pressure and stress are concentrated. A secure connection is essential for safe operation.
When inspecting couplings and clamps, focus on:
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Alignment - if fittings are misaligned, it increases stress and wear.
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Security - clamps and couplings should be tight and show no signs of slipping.
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Condition - look for cracks, corrosion or distortion.
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Testing - the only way to confirm performance is through a pressure test that simulates real operating conditions.
Using the right fitting for the job also matters. A mismatched or low-quality coupling can compromise an otherwise good hose. At JML Henderson, a full range of couplings are available - including Camlock, Storz, DIN 11851 and Unicone - so assemblies can always be built to the correct specification.
The Role of Testing
A visual check alone is not enough. Many faults only show up when a hose is pressurised. That’s why hydrostatic pressure testing is part of best practice.
JML Henderson carry out testing to BFPA (British Fluid Power Association) standards. This involves safely increasing pressure within the hose while checking for leaks, bulges or other failures. Where required, electrical continuity checks are also carried out, ensuring conductive hoses are safe for use in ATEX or static-sensitive environments.
Once testing is complete, certification is supplied. This gives you the documentation needed for compliance and audit records, and reassurance that your hoses are safe for service.
Compliance and Safety Standards
Hose inspections and testing aren’t just good practice - they are often essential for compliance. Industries from chemicals to food and pharmaceuticals have strict safety rules, and failure to meet them can lead to legal, financial and reputational risks.
By following BFPA best practice and ISO guidelines, you can be confident that your hoses are not only working but are also operating within industry expectations for safety and reliability. This is where working with a trusted supplier makes a real difference.
How JML Henderson Can Help
At JML Henderson, hose inspections are more than a quick look over. Our service includes:
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Thorough visual checks for wear, cracks, blisters or damage
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Careful inspection of couplings and clamps
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Hydrostatic pressure testing to BFPA best practice
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Electrical continuity checks where required
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Certification and tagging for easy traceability
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Re-ending, shortening and reconditioning where hoses can be economically repaired
This approach ensures every assembly is safe, traceable and fit for duty. Whether you need a one-off inspection or a regular service plan, we’ll help keep downtime off your schedule and reduce long-term costs.
Final Thoughts
Industrial hoses may seem simple, but they play a critical role in keeping operations safe and productive. By making inspections a routine part of your maintenance plan, you can extend hose life, improve safety and protect your bottom line.
With expert support from JML Henderson, you’ll have the confidence that your hoses are tested, certified and ready for the demands of your operation.
📞 01406 362978
🌐 jmlhenderson.co.uk
